Improving The Life Of Gearboxes & Lowering Repair Costs

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1 Improving The Life Of Gearboxes & Lowering Repair Costs

2 State of the Art Manufacturing Facilities & Heat Treatment Pioneer 35 years experience Certified supplier network Moventas material specifications Cleanliness levels ME/AGMA grade 3 quality level inspections State of the art superfinishing processes 100 % Grinding burn inspection Full component traceability

3 In-house Manufacturing To ensure the highest quality and durability of gearbox components, Moventas keeps key design & manufacturing processes in-house. ISO 9001, ISO 14001, OHSAS certified Metallurgy Case carburizing Inspections & Testing Castings Ring gears Planet gears Hollow shafts High-speed shafts Intermediate speed assemblies

4 Let s Going Deep Right Into It; Part I: Improving The Life Cycle Of Your Gearboxes The ones you must do! Monitoring; From day one! Inspections; Maintenance; Upgrades/Repairs; End of Warranty; The ones you don t want to do! Gearbox design: Site Specific flaws:

5 Monitoring: From day one! From commissioning: Oil sampling: Noises: Vibrations: Temperatures: Service Reports: Trends:

6 CMaS Condition Management System Sophisticated remote monitoring system for drivetrains. Developed specifically for wind gear use, to prevent unexpected disturbances in energy generation. Predictive maintenance tool, proved to reduce OEM maintenance costs. Identifies potential causes of damage with seven parametres. Can be installed on both new and old equipment. Easy interface for the customer to use Can also be complemented with remote management service by Moventas experts.

7 Let s Going Deep Right Into It; Part I: Improving The Life Cycle Of Your Gearboxes The ones you must do! Monitoring; From day one! Inspections; As soon as a doubt appear! Maintenance; Upgrades/Repairs; End of Warranty; The ones you don t want to do! Gearbox design: Site Specific flaws:

8 Inspections: As soon as a doubt appear! Inspections: Use all your senses: Use Expert Services:

9 The Gearbox Case Study of the Year; Direct Drive WTG

10 Let s Going Deep Right Into It; Part I: Improving The Life Cycle Of Your Gearboxes The ones you must do! Monitoring; From day one! Inspections; As soon as a doubt appear! Maintenance; Ever seen a GBX maintenance manual? Upgrades/Repairs; End of Warranty; The ones you don t want to do! Gearbox design: Site Specific flaws:

11 Maintenance: Ever seen a GBX O&M Manual? Maintenance: Preventive:Good practices Corrective: Don t wait till it fail Predictive: Extending the life Importance of good housekeeping: Detecting leaks.

12 Let s Going Deep Right Into It; Part I: Improving The Life Cycle Of Your Gearboxes The ones you must do! Monitoring; From day one! Inspections; As soon as a doubt appear! Maintenance; Ever seen a GBX maintenance manual? Upgrades/Repairs; BHT! End of Warranty; The ones you don t want to do! Gearbox design: Site Specific flaws:

13 Repairs & Upgrades: BHT! What s are your expectations? Repair cheap or last? Upgraded Components Extra-Life Series Key to success life-cycle extension

14 Let s Going Deep Right Into It; Part I: Improving The Life Cycle Of Your Gearboxes The ones you must do! Monitoring; From day one! Inspections; As soon as a doubt appear! Maintenance; Ever seen a GBX maintenance manual? Upgrades/Repairs; BHT! End of Warranty; The must of the must, why wait! The ones you don t want to do! Gearbox design: Site Specific flaws:

15 End Of Warranty: The must of the must, why wait? Where lies the knowledge? Transparency Open Book Remember: Undiscovered problems affect your budget and wallet

16 Let s Going Deep Right Into It; Part I: Improving The Life Cycle Of Your Gearboxes The ones you must do! Monitoring; From day one! Inspections; As soon as a doubt appear! Maintenance; Ever seen a GBX maintenance manual? Upgrades/Repairs; BHT! End of Warranty; The must of the must, why wait! The ones you don t want to do! Gearbox design: If the original one wasn t good enough Site Specific flaws:

17 Gearbox design: If the original one wasn t good enough! Design loads & Testing's: Materials & Finishes: Manufacturing processes:

18 Let s Going Deep Right Into It; Part I: Improving The Life Cycle Of Your Gearboxes The ones you must do! Monitoring; From day one! Inspections; As soon as a doubt appear! Maintenance; Ever seen a GBX maintenance manual? Upgrades/Repairs; BHT! End of Warranty; The must of the must, why wait! The ones you don t want to do! Gearbox design: If the original one wasn t good enough Site Specific flaws: Remember what the sales guy said

19 Site Specific Flaws: Remember what the sales guy said Site Suitability: Capacity Factor, Wind Speed & Turbulence, Etc: Wake, Slope Effects: Wind Turbines Operating Specifications: Certainly not returning to original WTG spec s..manage the risks!

20 Let s Going Deep Right Into It; Part I: Improving The Life Cycle Of Your Gearboxes The ones you must do! Monitoring; From day one! Inspections; As soon as a doubt appear! Maintenance; Ever seen a GBX maintenance manual? Upgrades/Repairs; BHT! End of Warranty; The must of the must, why wait! The ones you don t want to do! Gearbox design: If the original one wasn t good enough Site Specific flaws: Remember what the sales guy said Litigation: TSA, MSA, WMSA been at the forefront!

21 Litigation: Up-front contract management Always involve OP s in contract! Contractual clarity. Managing Operating Risks.

22 Let s Going Deep Right Into It; Part II: Lowering Repair Costs Repairs Retrofits Upgrades Description: What? Does I m paying for that? Up-Tower, Down-Tower, Workshop, Replacement Possibilities: Is up-tower possible? Down-tower? Workshop? Replacement: No chances, need to replace! Wise decision? New Methods, Costs & Cases method: Replace a gearbox in less than 3 days, yes we ve done it! Repair kits: Just replace the broken parts type Modules Swap: The in between solution!

23 Repairs Retrofits Upgrades Repairs: Retrofits: Upgrades: Something is broken They discover a problems - Recall They discover a problems & They want me to pay for the fix! Make sure you read the contract before!

24 Moventas Multi-Brand Service

25 Moventas Multi-Brand Service Spare Parts and Special Tools Diagnostics Modernisations Factory Service Inspections and Assessments Field Service Extended Warranties Analysis Services Replacements Service Contracts Condition Management

26 Let s Going Deep Right Into It; Part II: Lowering Repair Costs Repairs Retrofits Upgrades Description: What? Does I m paying for that? Up-Tower, Down-Tower, Workshop, Replacement Possibilities: Is up-tower possible? Down-tower? Workshop? Replacement: No chances, need to replace! Wise decision? New Methods, Costs & Cases method: Replace a gearbox in less than 3 days, yes we ve done it! Repair kits: Just replace the broken parts type Modules Swap: The in between solution!

27 Full Service Scope for the Entire GE 1.5 Fleet Complete Up-tower repair capability Reduced crane costs Modernized upgraded solutions Moventas has reverse engineered Winergy PEAB 4410 & PEAS 4390 Bosch Rexroth GPV451 & GPV453 Eickhoff CPNHZ-195 Moventas has the complete ability to repair and manufacture or source any component Improve predictive maintenance with CMaS Main shaft repairs and modernizations + 2,000 Up-tower endoscope analysis & end of warranty inspections + 10 Up-tower planetary repairs Up-tower helical repairs Up-tower HSS & IMS bearings & shafts replacement

28 Why Extra Life? Extra Life for GE 1.5 turbine drivetrains Remove known premature failure modes to extend gearbox lifetime Extended warranty for your fleet Spot problems early on and solve them on-site Save money, reduce downtime and decrease OPEX Available for multi-brand replacements, refurbishments, up-tower services and spares Reliable partnership and proven quality with a gearbox OEM Moventas 35-year wind industry experience and core technologies harnessed for service fleets

29 Extra Life for GE 1.5 Replacement Gearbox Strongest planetary stage with case carburized gears and integrated planet bearings Improved gear design with even better pitting and scuffing resistance White Etch Cracking resistance extends bearing life Eliminates inclusion derived tooth breakage with upgraded material for the intermediate speed gearing Enhanced lubrication filtration and moisture prevention to increase gear and bearing life Condition Monitoring 24/7 Excellent up-tower serviceability The industry s most comprehensive Five-year Warranty covers crane costs and lost revenues during downtime

30 Professional Field Service Our Texan team working on an up-tower job in Oregon. On-site service by Moventas often saves the customer dozens of thousands of euros.

31 The wise and safety tip! Always test a new repair/exchange procedure on the ground and in the shop before going uptower. Practices and simulations with the tools and lifting gears is a must to discover where the risk are! Remember the Devil is in details and its costly in both; risks and $!

32 Let s Going Deep Right Into It; Part II: Lowering Repair Costs Repairs Retrofits Upgrades Description: What? Does I m paying for that? Up-Tower, Down-Tower, Workshop, Replacement Possibilities: Is up-tower possible? Down-tower? Workshop? Replacement: No chances, need to replace! Wise decision? New Methods, Costs & Cases method: Replace a gearbox in less than 3 days, yes we ve done it! Repair kits: Just replace the broken parts type Modules Swap: The in between solution!

33 Replacement Schedule GE Sle 1.5 Day 1 - Prep Shut down turbine Remove all external gearbox connections + drain GBX Day 2 - Crane Day Remove cover Lift tool box, manage all up-down operations, lift & Install mainshaft clamp Push back and remove old gearbox Lift new gearbox and reinstall Remove mainshaft clamp, take down tool box Put cover back Day 3 - Wrap Up Torque shrink element / Install brakes and coupling Reinstall all wiring and sensors Refill with oil Perform final checks and place back in service

34 Replacing

35 Let s Going Deep Right Into It; Part II: Lowering Repair Costs Repairs Retrofits Upgrades Description: What? Does I m paying for that? Up-Tower, Down-Tower, Workshop, Replacement Possibilities: Is up-tower possible? Down-tower? Workshop? Replacement: No chances, need to replace! Wise decision? New Methods, Costs & Cases method: Replace a gearbox in less than 3 days, yes we ve done it! Repair kits: Just replace the broken parts type Modules Swap: The in between solution!

36 New Parts & Replacement Kits

37 Let s Going Deep Right Into It; Part II: Lowering Repair Costs Repairs Retrofits Upgrades Description: What? Does I m paying for that? Up-Tower, Down-Tower, Workshop, Replacement Possibilities: Is up-tower possible? Down-tower? Workshop? Replacement: No chances, need to replace! Wise decision? New Methods, Costs & Cases method: Replace a gearbox in less than 3 days, yes we ve done it! Repair kits: Just replace the broken parts type Modules Swap: The in between solution!

38 Siemens 2.3 Planetary Section Replacement Our proposed replacement procedure for Siemens 2.3MW planetary sections will roughly mirror our successful methods from the GE 1.5MW Use of Liftra TM mainshaft clamp Splitting gearbox in two Removing each section seperately to reduce max lift Basic order of operations: 1: Old helical down 2: Old planetary down 3: New planetary up 4: Old helical up First GE 1.5MW Up-tower Planetary Repair Panther Creek - September 2015

39 Replacement Schedule Siemens 2.3 Day 1 - Prep Shut down turbine Remove all external gearbox connections + drain GBX Day 2 - Crane Day Remove cover Lift tool box, manage all up-down operations, lift & Install mainshaft clamp Helical section remove and lowered to the ground, in the MSU Planetary section remove and lowered to the ground New planetary lift and re-installed Helical section re-installed Remove mainshaft clamp, take down tool box Put cover back Day 3 - Wrap Up Torque shrink element / Install brakes and coupling Reinstall all wiring and sensors Refill with oil Perform final checks and place back in service

40 Planetary Module Exchange on Siemens 2.3

41 Questions & Information's: Daniel Charette Territory Sales Manager; Eastern Canada, US Northeast & US Mid-Atlantic Thank you

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